Systems and Methods for Object Processing with Programmable Motion Devices Using Vacuum Slider Grippers

This application claims priority to U.S. Provisional Patent Application No. 63/754,366 filed February 5, 2025, the disclosure of which is hereby incorporated by reference in its entirety.

The invention generally relates to programmable motion systems and relates in particular to end-effectors for programmable motion devices (e.g., robotic systems) for use in object processing systems such as object sortation systems.

End-effectors for robotic systems may be employed, for example, in certain applications to select and grasp an object, and then move the acquired object very quickly to a new location. End-effectors should be designed to quickly and easily select and grasp an object from a jumble of dissimilar objects, and should be designed to securely grasp an object during movement. Certain end-effectors, when used on different objects of different physical sizes, weights and materials, may have limitations regarding how securely they may grasp an acquired object, and how securely they may maintain the grasp on the object during rapid movement, particularly rapid acceleration and deceleration (both angular and linear). Further, in certain applications it may be desired to place an object at a destination in a required orientation or pose, particularly with respect to an environment such as a container being packed by a robotic system.

Many end-effectors employ vacuum pressure for acquiring and securing objects for transport and/or subsequent operations by articulated arms. Other techniques for acquiring and securing objects involve electrostatic attraction, magnetic attraction, needles for penetrating objects such as fabrics, fingers that squeeze an object, hooks that engage and lift a protruding feature of an object, and collets that expand in an opening of an object, among other techniques.

In applications where vacuum pressure is used to acquire and secure objects, an end-effector on an articulated arm may include a vacuum cup having a compliant portion, e.g., a bellows portion that contacts the object to be grasped. The compliant portion may be formed of a polymeric or elastomeric material that is flexible enough to allow it to change its shape to adapt to variations in object surface structures, and to varying physical relationships between the articulated arm and the object, such as for example varying angles of approaches to objects. The flexibility further allows the vacuum cup to conform to the shape of objects or to wrap around corners of objects to create an adequate seal for acquiring and securing the object.

Other types of end-effectors including vacuum cups with less flexible compliant portions (in addition to those using electrostatic attraction, magnetic attraction, needles for penetrating objects such as fabrics, fingers that squeeze an object, hooks that engage and lift a protruding feature of an object, and collets that expand in an opening of an object), are less effective at acquiring and moving a wide variety of objects.

Such applications in which a robotic system needs to accurately process a wide variety of sizes of objects relative to an environment include, for example, packing multi-unit e-commerce orders into a container, packing a single unit into an automated bagging system, packing or consolidating containers used in an automated storage and retrieval system (AS/RS), and scanning objects in front of scanners such as barcode scanners or RFID scanners.

Vacuum end-effectors however, may be limited in their ability to acquire objects of a wide variety of sizes, such as if the object being processed includes a small or narrow face that is exposed to the end-effector. For example, bins of thin objects that are tightly packed in an input bin present certain challenges including how to properly access and grasp an object, as well as how to avoid grasping multiple objects.

Further, objects may sometimes be encountered that have internal degrees of freedom when grasped, such as an unsealed shoe box, an unsealed book or a folded pair of pants. Such objects may open if lifted by a single surface. Additionally, traditional pinch grippers and vacuum cup grippers may have difficulty accessing individual objects in densely-packed totes from a warehouse.

There remains a need therefore, for systems and methods for more efficiently and effectively grasping, manipulating, and packing objects by efficiently acquiring objects of a wide variety of sizes without adversely impacting throughput.

In accordance with an aspect, the invention provides an object processing system that includes an input area at which objects are presented to a programmable motion device, a perception system for providing perception data regarding an object to be processed that is at the input area and an end-effector operatively coupled to the programmable motion device. The end-effector includes a first contact portion and a second contact portion, each contact portion configured to engage an external surface of an object and each contact portion comprising at least one vacuum opening. The first and second contact portions are positioned non-parallel relative to one another to allow the end-effector to engage the object on separate surfaces. The second contact portion provides a converging movement relative to the first contact surface, and moves a converging slider relative to the second contact portion.

In accordance with another aspect, the invention provides an object processing system that includes an input area at which objects are presented to a programmable motion device, a perception system for providing perception data regarding an object to be processed that is at the input area, and an end-effector coupled to the programmable motion device, the end-effector including a first contact portion and a second contact portion, each of the first and second contact portions being generally planar and each including at least one opening through which vacuum may be provided, the second contact portion being generally non-parallel to the first contact portion, and the second contact portion being movable with respect to the first contact portion at least in an engagement direction such that more than one surface of the object may be grasped by the end-effector. In some embodiments, the contact portions may be non-planar, including curved, angled, or conformable surfaces. The shape of each contact surface may be selected to match an object profile or to optimize vacuum engagement on irregular or flexible objects. In some embodiments, the contact portions may be positioned at non-perpendicular angles to accommodate specific object geometries or system constraints.

21 60 62 2 5 FIGS.and In another aspect, an object processing system is provided that includes an input area at which objects are presented to a programmable motion device, a perception system for providing perception data regarding an object to be processed that is at the input area, and an end-effector coupled to the programmable motion device, the end-effector including a first contact portion and a second contact portion, each of the first and second contact portions being generally planar and each including at least one opening through which vacuum may be provided, the second contact portion being generally non-parallel to the first contact portion, and the first contact portion including an actuator for adjusting a volume of vacuum flow at the first contact portion. While some embodiments include a perception subsystem to identify an exposed surface of the object (e.g., perception units,, andin), other embodiments may operate based on predefined object positions, stored object geometry, or external input. In such cases, the system may engage an object without actively analyzing its orientation or face.

In yet another aspect, a method of processing objects in an object processing system is provided that includes receiving an object at an input area proximate a programmable motion device, providing an end-effector coupled to the programmable motion device, the end-effector including a first contact portion and a second contact portion, each of the first and second contact portions being generally planar and each including at least one opening through which vacuum may be provided, the second contact portion being generally orthogonal to the first contact portion, moving the second contact portion with respect to the first contact portion at least in a direction that is generally non-parallel to the first contact portion and contacting more than one surface of the object to grasped by the end-effector.

Applicants have discovered that end-effectors may be provided that may effectively and efficiently grasp items including, but not limited to, books, shoe boxes, and other common items with internal degrees of freedom using vacuum actuation, be integrated into a cup swap system with standard suction cups, may either be mechanically or electromechanically actuated to adapt to different book/shoe box sizes, and may detect changes in vacuum pressure for sensing grasps. In accordance with various aspects, the invention provides a book/shoe box gripper that includes a main housing, to which the following components are mounted: a compliant gripper attachment, a horizontal slider housing and linear rail/bearing, and a converging (e.g., vertical) slider.

Object processing systems in accordance with various aspects of the invention employ any of a variety of high flow vacuum end-effectors that are used for different objects during object processing as discussed herein. A challenge with using high flow vacuum is that if the vacuum cup contact surface contacts plural objects, the plural objects may all be grasped because the high flow vacuum system does not require that the vacuum cup tightly seal a closed surface area of the object being grasped. Using a vacuum cup therefore that contacts plural objects may well grasp many of the plural objects using the high flow vacuum.

75 14 84 84 14 FIGS.A 12 FIG.B 12 FIG.B As used herein, a “contact portion” refers to a region or structure of the end-effector that includes a vacuum engagement surface, and may include sliders, flaps, combs, channels, or other mechanical components for modulating vacuum or positioning, such as contact portion(horizontal slider) shown in–C, and contact portion(converging, e.g., vertical slider) shown in. A “contact surface” refers to the specific face or region of a contact portion that interfaces with the object. An “engagement direction” refers to the direction of motion used to bring the second contact portion toward the object or the first contact portion, such as the downward movement of contact portionin.

Applicants have discovered that a vacuum applicator may be provided that can wedge into spaces to separate objects and then access a side surface of an object for application of suction. Simply mounting a suction cup on a sideways mount would not provide the correct structure because standard suction cups often have bellows that are designed to provide compliance when aligning from above however this compliance when grasping from the side allows an object to create a torque that makes the grip weaker, and is difficult to use as it creates a bulky structure that cannot wedge between objects. In accordance with various aspects the invention provides an end-effector that can wedge between objects, that can grasp objects using only suction and friction from one side, that are compliant enough to conform to the face of an object, and that can grasp thin objects without damaging them.

1 FIG. 2 FIG. 10 12 14 20 20 34 12 16 17 18 26 22 24 28 shows an object processing systemin accordance with an aspect of the present invention that includes an input source conveyorthat provides objects to be processed to a processing stationthat includes a programmable motion device. The programmable motion deviceis used to grasp and move objects received at an input area(shown in) from the input source conveyor, and to provide objects to any of an auto-bagging systemthat provides objects in sealed bagsalong an auto-bagging system conveyor, or to provide objects to output containers(e.g., shipping boxes) provided at a packing areaon a container output conveyor. The objects to be processed may be provided in input source containers.

2 FIG. 2 FIG. 12 28) 34 34 52 54 12 52 54 30 26 32 14 22 24 100 36 100 With further reference to, a top view shows the input source conveyorthat brings input objects (e.g., in binsto the input area. The input areaincludes two conveyor sections,that receive objects from the input source conveyor, and both conveyor sections,lead to a source container return conveyoras shown in. Empty output containersare provided along an empty output container conveyorto the processing station, and are routed to the packing areawhere they are packed prior to being moved along the container output conveyor. Operation of the conveyors and other components of the system is provided by the one or more computer processing systemsas discussed herein, and the programmable motion device may include its own processing control systemin communication with the one or more computer processing systems.

1 FIG. 4 FIG. 20 38 38 40 100 With reference again to, the programmable motion deviceincludes an end-effector attachment portion (shown in more detail in) that is coupled to a high flow vacuum source, such as for example, a side-channel blower, air amplifiers or multistage ejectors. The high flow vacuum sourcemay, for example, provide at the end-effector attachment portionan air flow of at least aboutcubic feet per minute, and a vacuum pressure of no more than about 100,000 Pascals below atmospheric, or no more than about 85,000 Pascals below atmospheric, or no more than about 65,000 Pascals below atmospheric. Again, the use of such a high flow vacuum source, while providing benefits in grasping objects where a seal is not tightly formed between the vacuum cup and the object, presents challenges in grasping only one object among a plurality of objects.

3 FIG. 4 FIG. 42 40 34 50 52 44 46 44 46 40 48 20 48 50 38 With reference to, an end-effectormay be attached to the end-effector attachment portionof the programmable motion device. Objects are received at an input area, either individually or in groups on input conveyor sections,or in bins or totes as shown. Plural additional end-effectors may be provided on one or more end-effector racks,as further shown in. The programmable motion device is programmed to be able to engage and disengage any of the end-effectors on the racks,as further discussed below. The end-effector attachment portionis mounted within a collarthat is attached to the programmable motion device, and an opposite end of the end-effector attachment portion (that extends out the other side of the collar) is coupled to a vacuum hosethat is coupled to the vacuum source.

5 FIG. 3 5 FIGS.and 2 FIG. 6 FIG. 2 FIG. 29 34 52 54 52 54 56 42 58 56 62 21 60 12 62 36 100 26 17 As shown in, exemplary objectsto be processed by the system may come in a variety of sizes, with varying exposed face sizes available for grasping. The system receives such objects at an input area, which defines a region accessible to the programmable motion device and is shown in. The input area 34 includes two conveyor sectionsand(shown in), which deliver containers or trays into the reach of the end-effector. In certain applications, these conveyor sections may operate independently or cooperatively and may optionally include right-angle-transfer mechanisms (e.g., raisable belts) to reposition containers between the conveyor sectionsand. An input container (e.g., container) may include objects with a large aspect ratio but only small-sized faces exposed to the programmable motion device. In accordance with an aspect of the present invention, the system may select an end-effector (e.g.,) to grasp n specific objectfrom the input container, as shown in. A perception system (e.g., including perception unitsand perception unitshown in) provides perception data regarding an object that is in the input area, and this data includes information representative of an exposed face of the object and may be used to determine which end-effector to use and how to engage the object. The system may include conveyor perception unitsalong the input source conveyoras well as the perception unitson the support structure from which the programmable motion device is suspended to support (together with the computer processing systems,) in operation of grasping, moving and placing objects into any of, for example, output containersor sealed bagsas discussed herein. While perception units may be used to analyze the orientation or visible surface of an object, in some implementations, object handling is based on known pick locations or object classifications without live sensor feedback.

7 FIG. 6 FIG. 42 80 66 40 61 66 74 72 70 88 44 46 88 40 72 40 With further reference to, the end-effectorincludes a housingthat is coupled via an attachment assemblyto the end-effector attachment portion(shown in) at the proximal end of the housing, and in particular, at an opening of an elbow-shaped (right angle) channel. The attachment assemblyincludes a housing mountattached thereto that is coupled at its proximal end to a flexible bellows, that is attached to a coupling collar, that is attached to an annular mounting ringthat permits the end-effector to engage with a rack,. The annual mounting ringattaches the end-effector to the attachment portion. The flexible bellowspermits substantial freedom of movement (e.g., pitch and roll) with respect to the end-effector attachment portion.

72 11 11 FIGS.A andB The housing attaches to the vacuum source through the compliant gripper attachment. The gripper attachment has a set of bellows, which give the gripper enough compliance to adapt to errors in the positioning of the robotic arm relative to items that it is attempting to grasp. In accordance with certain aspects (as discussed below with reference to) the gripper attachment also may include two grooves, which lock into locating features mounted to a suction tube that is attached to a robot arm. The robot can twist this suction tube, allowing it to automatically lock into place. This allows the robot to swap between various types of grippers, including the book/shoe box gripper. The locating features also resist forces and torques that could otherwise cause the gripper to fall off the suction tube.

In accordance with certain aspects, the invention provides an end-effector system for programmable motion devices (e.g., robotic systems) that provides high flow vacuum together with one or more sliders that facilitate accommodating objects of various sizes, weights and objects having internal degrees of freedom. The high flow vacuum is provided at an end-effector vacuum applicator of the robotic system, and the vacuum applicator is coupled to a high flow vacuum system. The vacuum applicator is attached to a cup attachment portion, which is in turn attached to an arm attachment portion that is attached to an articulated arm of the robotic system.

7 FIG. 8 8 FIGS.A andB 42 76 75 73 77 73 81 64 80 73 75 63 80 69 79 75 With continued reference to, the end-effectoralso includes a vacuum flow control mechanism, such as a horizontal slide adjustment system (actuator)that includes a flexible horizontal sliderwith an attached slider taband a volume-blocking combon the underside. The slider tabrides with a linear bearingalong a horizontal railmounted on the housing. As the slider tabis moved, the flexible horizontal slideris urged downward and in a reverse direction by an inner curved surfacewithin the housing. A flexible flap(shown in) and a sealing foamare mounted to the leading edge of the flexible horizontal slide. The horizontal slide adjustment system and the vertical slide adjustment system are generally mutually perpendicular (e.g., within 80 degrees to 100 degrees of each of other), and provide the vacuum force where the two slide adjustment systems join at a vacuum corner edge. Additionally, the vertical open channels and the horizontal open channels are provided between ridges (e.g., plastic or metal) that maintain their shape under the force of the vacuum, permitting the vacuum force applied to the object to be evenly distributed while maintaining the openness of the channel to provide the vacuum.

8 12 FIGS.B,B 14 While the first and second contact portions are shown in the figures as being generally orthogonal—such as the vertical and horizontal contact surfaces shown in, andA—this particular angular arrangement is not required, and the first and second contact portions may generally be non-parallel. In other embodiments, the contact portions may be positioned at non-orthogonal angles, including acute or obtuse configurations, depending on the geometry of the objects to be grasped or the spatial layout of the system. For example, contact surfaces may be arranged at angles of 30°, 45°, 60°, 120°, or other non-right angles, either fixed or adjustable. In some cases, one or both contact portions may be formed of or supported by compliant or flexible materials, such that the effective engagement angle may vary dynamically during object contact. The angular relationship between contact portions may be selected to optimize surface contact, packing efficiency, or system integration, and may include curved transitions between surfaces in some embodiments.

75 73 75 77 75 69 The horizontal slideris designed to be thin, flexible, and housed within a track in the horizontal slider housing. As the tabof the horizontal slideris pushed inward and outward, it expands and contracts the horizontal suction surface at the distal end of the gripper. The horizontal slider wraps around the track and makes a 180° turn inside its housing. This design allows the gripper to be more compact, allowing it to more effectively operate in cluttered warehouse totes. The slider also has “teeth” on the volume-blocking combon its bottom side, which act as seals inside the horizontal slider housing to direct the incoming air in the desired direction. The need for these “teeth” instead of one continuous surface is due to the need for a support structure in the housing under the horizontal slider to support it under high vacuum pressure. This prevents low pressure from building up in the closed region of the gripper, which can result in unintended picks. This slideralso has the flexible flapmounted to the leading edge, allowing it to seal around various surfaces of books, shoe boxes, and other items.

79 81 81 81 64 73 18 18 FIGS.A,B The additional piece of rubber foamis added on the leading edge as well to better seal against the edges of SKUs to prevent unintentional/multi-picks. Flexible flapsare mounted on the sides of the horizontal slider housing to fully seal the horizontal suction surface. The flexible flaps(e.g., rubber flaps) are drawn by the vacuum to urge against an object being grasped to further engage and grasp the object. The horizontal slider can be relatively fragile, so the slider tab is mounted to a linear bearingand railto isolate it from external forces and torques. The tabinteracts with a gripper adjustment plate mounted in the robotic cell in which it is being operated (as discussed below with reference to), which allows the robot to adjust the grippers’ slider lengths prior to it grasping an item.

42 86 84 82 80 85 84 61 89 80 85 84 80 87 84 85 87 87 85 61 7 FIG. The end-effectorfurther includes a vertical slide adjustment systemthat includes a converging slider such as a vertical sliderthat rides along a vertical trackon the housing. The converging slider provides converging movement of the second contact portion relative the first contact portion, and in accordance with certain aspects, the movement of the second contact portion will increase or decrease the amount of vacuum flow at the at least one opening of the second contact portion. The converging movement is generally non-parallel to the first contact portion and may be ion an axial direction relative the programmable motion device (e.g., vertical as shown in) to provide, for example, a plunging movement relative the objects at the input area. An open cavityis provided on an inner side of the vertical slideris in communication with the distal end of the channel. A foam padmounted to the housingsubstantially seals the cavityat the upper end and provides a small degree on friction in movement of the vertical sliderwith respect to the housing. Distal vertical open channelsare provided at the distal end of the vertical sliderin communication with the cavity, and provide a generally planar contact surface at the channels. Vacuum is therefore drawn up through the distal open channels, through the cavity, through the channeland up through the end-effector mounting hardware to a hose and the vacuum source.

80 89 83 99 The converging (e.g., vertical) slider 84 of the gripper therefore mounts to the main housingand can slide up and down to adjust for the height of the object being grasped. An internal seal in the main housing prevents air from escaping between the housing and vertical slider when vacuum is applied by the foam pad. The flexible flaps(e.g., rubber flaps) are also drawn by the vacuum to urge against an object being grasped to further engage and grasp the object. The vertical slider has a wedged tipat its distal end, which allows it to effectively pry apart items that are packed tightly together to pick just one selected item. The vertical slider should have enough resistance to do this wedging action, but not too much resistance to sliding that the robot cannot adjust it at the gripper adjustment plate. Currently, the seal applies the resistance force through friction. However, this force could be increased with preloaded springs or spring pins. This force could also be temporarily increased by applying variable vacuum pressure. Since the main housing internal channels direct the air flow away from the vertical slider, it dramatically increases the friction between the main housing and vertical slider when vacuum is applied. This can be used to increase sliding resistance when wedging between books. Instead of using the gripper adjustment plate, the position of the vertical slider could also potentially be adjusted against a surface inside the tote of a known height (e.g., a book, bottom of tote) for faster adjustment than returning to the gripper adjustment plate. The vertical slider also has flexible flaps to better seal against uneven surfaces.

8 FIG.A 8 FIG.B 16 FIG.A 8 FIG.B 17 FIG.A 42 85 89 42 67 67 87 59 61 85 84 59 75 84 75 67 87 77 59 87 75 76 73 75 81 83 shows an elevated exploded view of the end-effectorshowing the open top to the cavitythat is sealed by the foam pad.shows an underside exploded view of the end-effectorshowing horizontal open channelsat the distal end of the end-effector. The horizontal open channelsare in communication with the vertical open channelsthrough openings(shown in). The vacuum is therefore provided via right angle channel, open cavityof vertical slider, and openingsto both the planar exposed surface of the horizontal sliderand the planar exposed surface of the vertical slider. The planar surface of the horizonal sliderand the planar exposed surface of the vertical slider are generally mutually orthogonal, permitting more than one surface of an object to be grasped by the contact portions of the horizontal open channelsand the contact portions of the vertical open channels(shown in). The teeth of the combfit with the horizontal open channels and direct the flow of vacuum from the distal end of the end-effector up into the horizontal open channels, through the openings(shown in) and into the vertical open channels. The volume of vacuum flow at the planar surface of the horizontal slideris therefore adjustable by the actuator. Again, as the tabof the horizontal slidermoves, more or less of the distal surface of the horizontal open channels are exposed to an object to be grasped. Again, the flexible flaps,(e.g., rubber flaps) are drawn by the vacuum to urge against an object being grasped to further engage and grasp the object.

In accordance with various aspects, the book/shoe box gripper may effectively grasp objects with internal degrees of freedom. Since the horizontal and vertical sliders are oriented about 90° from each other, they may keep items like books and shoe boxes closed throughout the picking process. The vertical and horizontal suction surfaces work together to lock these items into their current state, preventing unfurling or opening. For hardcover books, where the covers extend further outward than the pages, the flexible flaps seal against this uneven surface. Between each item type, the gripper can be reconfigured at the gripper adjustment plate to ensure it has the optimal suction surface dimensions for each item.

75 40 91 92 88 40 91 92 88 91 92 91 94 94 9 10 10 11 11 15 FIG.B 9 9 FIGS.A -D 9 FIG.A 9 FIG.B 9 FIG.C 9 FIG.D 9 FIG.C 9 FIG.D 9 FIGS.A In accordance with certain aspects, the gripper may only have one adjustable suction surface, with one being set to a constant size. In accordance with further aspects, no adjustable surfaces may be provided, e.g., cases where the items it is grasping are the same or similar sizes. Additionally, instead of using mechanical actuation to adjust the vertical and horizontal sliders, grippers may use electromechanical actuation (e.g., motors or linear actuators inside the gripper), which would significantly decrease the time required to configure the gripper as discussed in more detail below. In some embodiments, both contact portions are fixed in position, and object engagement is achieved solely through modulation of vacuum exposure using flow control features. For example, the first contact portionmay remain stationary with its vacuum openings partially or fully closed via a flow control mechanism, such as in, where the horizontal slider covers the openings. End-effectors in accordance with certain aspects of the invention may be used with a rack engagement system for automatically exchanging end-effectors. The system needs to know the yaw orientation of the end-effector on the attachment portion.for example, show an engagement system that includes a pin and a pin recess for alignment of the end-effector on the attachment portion. With reference to, a spring-loaded pinis provided on the attachment portion, and a pin recessis provided on the annular mounting ring. During use in attaching the end-effector, the programmable motion device positions the attachment portionabove the end-effector on the rack, in which the pinand the recessare not yet aligned (). The attachment portion is lowered further, and the pin contacts the annular mounting ring(). The end-effector attachment portion is then rotated until the pinengages the pin recess(). The retracted position of the pin(shown in) is designed such that the magnetic fields of the magnetsare not yet so strong as to inhibit rotation of the attachment portion with respect to the end-effector. In accordance with further aspects, the magnetsmay be provided as electromagnets that may be engaged only when the pin has been received within the pin recess (). In this example, the attachment portion rotates until it is aligned with the end-effector on the rack. In some embodiments, the end-effector is modular, and may be exchanged using an automated rack system, such as those shown in–D,A–B, andA–B. This enables dynamic selection and deployment of different end-effectors based on object type or task.

10 10 FIGS.A andB 10 FIG.A 10 FIG.B 9 10 FIGS.A -B 40 94 96 42 95 97 40 42 42 42 40 40 In accordance with further aspects, the magnets used for engaging the attachment portion to the annular attachment ring of the end-effector may themselves effect proper alignment of the end-effector with the attachment portion., for example, show another attachment portion’ that includes s-magnetsand p-magnets, while the end-effector’ includes n-magnetsand s-magnets.shows the magnets, andshows the attachment portion’ coupled to the end-effector’, showing that the end-effector’ has been rotated under the polar forces of the magnets to both align with and engage the end-effector’ with the attachment portion’. The p-magnets align with the s-magnets, so irrespective of the original orientation of the end-effector with respect to the attachment portion, the parts will come together in one of two mutual orientations that are 180º apart; either orientation works because the end-effectors are symmetric. In accordance with further aspects, sets of magnets may be used that couple only in a single respective orientation of each end-effector and the attachment portion. In accordance with certain aspects, the attachment portion’ may also (or instead) be rotated to the alignment position. In each of the systems of, the control system may know or confirm the identity of each end-effector either by a scanner or camera system that detects a code on each end-effector or by providing low level magnets that detect low level distinct field patterns identifying each end-effector.

112 110 40 112 112 110 11 11 FIGS.A andB 11 FIG.A 11 FIG.B In accordance with further aspects, systems of invention may include locating featuresthat fit into groovesas shown in.shows an underside of the end-effector attachment portionwith the locating featuresextending distally, andshows the locating featureslocked in the grooves(only one is shown). These such locating features may provide additional torsional rigidity to the system.

84 29 28 84 87 42 56 26 16 75 84 84 84 80 12 FIG.B 5 FIG. 12 17 FIGS.B andA 6 FIG. 1 FIG. 22 FIG. 12 FIG.A 12 FIG.B The wedge-shaped distal portion of the vertical slider(shown in) may be moved between adjacent objectsin an input container such as input bin(shown in) to create sufficient space for engagement with an individual object surface. The movement of the vertical slidermay be substantially downward or along another engagement direction to bring the contact surface into alignment with an object to be grasped. While in some embodiments this movement resembles a downward "plunge," in other embodiments the vertical slider may be moved through linear, rotational, or compliant motion to achieve the desired alignment. The high-flow vacuum is active during this engagement movement, and the vacuum force applied to the object increases as a greater portion of the vacuum openings (e.g., vertical open channelsin) come into proximity with the object surface. Through force feedback or motion-based inference—such as detecting resistance, actuator current, or position stall—the system may determine when sufficient engagement has been achieved and may cease further movement of the end-effector(shown in). Once engaged, the object is lifted from the binand processed by being placed into an output containeror into the bagging station(shown in). The horizontal sliding system may also be adjusted as appropriate to maintain sufficient contact with the selected object without engaging adjacent objects. For example, if the object presents a thin exposed face (e.g., books on end as shown in), the horizontal slidermay be adjusted to expose only a narrow vacuum surface. .shows the vertical sliderin a retracted position andshows the vertical sliderin an extended position. Again, the position of the vertical sliderwith respect to the housingmay be achieved by pushing the vertical slider distally against a proximal end of the vertical slider, or by pushing the vertical slider proximally against a distal end of the vertical slider. For example, when moving toward an object such as a book on a conveyor or floor of a tote, the distal end of the vertical slider will move proximally against the conveyor or floor of the tote.

13 FIG.A 13 FIG.A 13 FIG.B 13 FIG.B 13 13 FIGS.A andB 8 FIG.B 18 18 FIGS.A andB 13 FIG.B 18 18 FIGS.A andB 120 84 84 76 78 68 80 73 68 68 73 73 67 73 134 130 132 130 132 With reference to, the position of the vertical slider may be controlled by one or more vertical position control systemsto either bias the position of the vertical slider downward (e.g., by a downward biased spring), or that actively drives the vertical slider downward and upward.shows the vertical sliderin a retracted position andshows the vertical sliderextended to an extended position along an engagement direction (downward as shown in).also show that the movement of the actuatordiscussed above may be powered, for example, by a motorthat drives a turn screwwithin the housing. The slider tabis attached to the driven turn screwby a threaded mount, and when the screwis rotated in one direction, the slider tabmoves in a forward direction, and the when reversed, the tabmoves in the rearward direction, adjusting the volume of vacuum flow at the planar horizontal surface provided by the open channels(again, shown in). In accordance with further aspects, the slidermay be moved by movement of the robot, and in particular, by bringing the end-effector adjacent a tab adjustment unitwith tab stops,as shown inand discussed in more detail below. While electric motors may be used (e.g., motor 78 in), actuation of the contact portions or sliders may also be achieved using pneumatic, hydraulic, magnetic, or electrostatic mechanisms. In some cases, actuation may occur by interaction with external features such as the tab stops,shown in.

14 14 FIGS.A -C 7 FIG. 14 FIG.A 14 FIG.B 14 FIG.C 17 FIG.A 75 73 77 79 69 63 show the horizontal slider system that includes the horizontal sliderwith the tabattached thereto at one end, and the volume-blocking comb, sealing foamand flexible flapattached at the other more distal end. The flexible horizontal slider is directed by the inner curved surface(shown in) as the tab is moved from an open position (), to an intermediate position (), to a closed position () in which the horizontal open channels (shown in) are closed.

15 15 FIGS.A andB 15 FIG.A 14 14 FIGS.A -C 8 17 FIGS.B andA 15 FIG.B 14 14 FIGS.A -C 17 FIG.B 75 73 67 75 73 67 show enlarged views of the horizontal slider system within the housing.shows the horizontal slider(shown in) and tabin a first position to fully open the planar contact surface provided by the horizontal open channels(shown in), andshows the horizontal slider(again shown in) and tabin a second position to fully close the horizontal open channels(also shown in).

16 FIG.A 16 FIG.B 17 FIG.A 61 80 85 84 87 67 75 69 67 85 61 66 With reference to, the distal end of the elbow-shaped channelin the housingis positioned adjacent the cavityin the vertical slideras further shown in. Again, vacuum is drawn through the vertical open channelsas well as any horizontal open channelsthat are not blocked by the horizontal sliderand seal(shown in). Such vacuum from the open horizontal open channelsand the vertical open channels is drawn via the cavityand channelthrough the end-effector attachment assemblyto the vacuum source.

17 FIG.A 17 FIG.B 18 FIG.A 18 FIG.B 73 67 73 75 79 73 73 42 73 130 134 42 73 132 134 shows the underside of the end-effector with the tabmoved to an open position to fully open the horizontal open channels, andshows the tabmoved to a closed position to fully close the horizontal open channels with the sliderand sealing foam. The position of the tabmay be changed using a motorized system such as a linear actuator as discussed above, or the position of the tabmay be changed by motion of the end-effector itself. For example,shows the end-effectormoving in a first direction such that the tabcontacts a first tab stopon a tab adjustment unit, andshows the end-effectormoving in a second opposite direction such that the tabcontacts a second tab stopon the tab adjustment unit.

End-effector grippers in accordance with various aspects of the invention include an adjustable vertical slider that slides vertically within the main housing to adjust for the height of objects being grasped, includes a wedge-shaped tip to pry apart tightly packed items and pick individual objects. In accordance with certain aspects, such end-effectors include a friction-based internal seals to prevent air leaks while providing resistance for wedging actions, and vacuum pressure within the housing increases sliding resistance to aid in wedging operations. In accordance with further aspects, adjustment may be performed using a gripper adjustment plate or by leveraging known surfaces within the tote or work environment for faster realignment. Flexible flaps on the vertical slider may also improve sealing against uneven surfaces in accordance with certain aspects of the invention.

End-effectors in accordance with further aspects include an adjustable horizontal slider that is provided as a thin and flexible component, and housed in a track within the horizontal slider housing, allowing it to expand or contract the horizontal suction surface. In certain aspects, the horizontal slider wraps around a 180° track, enabling a compact design for effective operation in tight spaces, like cluttered warehouse totes. The slider may include features “teeth” on the underside to direct airflow while maintaining structural support under high vacuum pressure, and may include a flexible flap and rubber foam on the leading edge to improve sealing against uneven surfaces and prevent unintentional or multi-picks. In accordance with further aspects, flexible flaps on the sides of the horizontal slider housing may be used to fully seal the suction surface. The adjustable horizontal slider is mounted on a linear bearing and rail to protect the slider tab from external forces and torques in accordance with certain aspects of the invention.

Additionally, a compliant gripper of various aspects of the invention integrates a set of bellows to provide compliance, allowing the gripper to adapt to positional errors of the robotic arm. Such an end-effector may be equipped with grooves that lock into locating features mounted on a suction tube, which connects to a robotic arm. The robot may twist the suction tube to automatically lock the gripper in place, enabling quick swapping between gripper types. Such locating features may resist forces and torques, preventing the gripper from detaching under load.

19 FIG. 17 17 FIGS.A andB 20 FIG. 21 FIG. 42 150 152 73 150 152 34 150 87 150 81 69 180 83 150 182 150 150 154 156 150 shows the end-effectorgrasping a bookon a flat surface. The horizontal slider tabmay be set to a position to provide the needed lift force on the facing surface of the book, and the vertical slider may be moved to contact the surfaceto engagethe end of the opposite cover of the book, thereby ensuring that the bookdoes not open when lifted. In particular, the vertical open channels(shown in) served to keep the book from opening since vacuum is passing therethrough.shows an enlarged view of the top surface of the cover of the bookbeing grasped by the flapas it is drawn down onto the book’s cover over the flexible flap(which compresses as shown at). The flapis also drawn inward against the covers of the bookas shown at. Once the distance of travel of the vertical slider is known for the object, such an objectmay then be picked from other objects,as shown inby knowing the thickness of the book and therefore knowing how far down the vertical slider should be positioned to grasp only the book.

22 FIG. 23 FIG. 42 73 160 99 84 150 81 184 83 150 186 Books may also be grasped on end.shows the end-effectorwith the horizontal slider tabpositioned to limit the horizontal opening to the thickness of a book(so as to avoid multi-picks), and the wedge-shaped tipof the vertical slidermay be used to plunge between adjacent books. In this way, tightly-packed vertically-standing books may be processed from a tote.shows an enlarged view of the top of the bookon end being grasped by the flapas it is drawn down onto the book’s end as shown at, and the flapis also drawn inward against the covers of the bookas shown at.

In accordance with specific aspects of certain end-effectors, the gripper’s horizontal and vertical sliders are motorized (and wirelessly controlled) and may be adjusted without mechanically moving them with methods such as the gripper adjustment tab stops. This may allow for faster adjustment between picks. In accordance with other specific aspects, the gripper may have no horizontal or vertical sliders but rather preset lengths that cannot be adjusted. This may be applicable, for example, for shoe boxes where having an exact length is not critical and since most shoe boxes have relatively similar dimensions.

24 FIG. 24 FIG. 42 73 42 172 174 170 172 174 172 , for example, shows the end-effectorwith the horizontal slider tabmoved to increase the openness of the horizontal open channels, and the vertical slider is moved to a lower position of its vertical range. The end-effectorofis thereby able to grasp together an openable topand front flapof a shoe boxsuch that the topand front flapdo not open. Such a shoe box could also be grasped from either side or even from the back of the box since the topwill remain closed.

In addition to books and shoeboxes, the system may be used to handle a variety of objects, including soft goods, electronics, retail packaging, food items, and tools. It may be deployed in e-commerce fulfillment centers, industrial automation environments, logistics hubs, postal facilities, or retail backrooms, among other settings.

In accordance with various aspects, therefore, the invention provides an object processing system that includes an input area, a perception system, and an end-effector. Objects are presented to a programmable motion device at the input area. The perception system provides perception data regarding an object to be processed that is at the input area. The end-effector is coupled to the programmable motion device, and includes a first contact portion and a second contact portion. Each of the first and second contact portions is generally planar and each includes at least one opening through which vacuum may be provided. The second contact portion is generally non-parallel to the first contact portion, and the second contact portion is movable with respect to the first contact portion at least in an engagement direction such that more than one surface of the object may be grasped by the end-effector.

In accordance with further aspects, the second contact portion is generally mutually orthogonal to the first contact portion, and wherein the engagement direction is generally orthogonal to the first contact portion. In accordance with yet further aspects, the movement of the second contact portion with respect to the first contact portion is spring-biased, or the movement of the second contact portion with respect to the first contact portion is actively powered. In still further aspects, the first contact portion includes an actuator for adjusting a volume of vacuum flow at the first contact portion. and/or the second contact portion includes channels that provide vacuum flow to both the first contact portion and the second contact portion. Movement of the second contact portion relative the first contact portion also adjusts the amount of vacuum flow at the second contact portion. In still further aspects, the actuator moves a slider to cover or expose the at least one opening in the first contact portion, and/or the actuator is actively powered.

Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the present invention.